Incontinent pad with high absorbent packet

Abstract

An incontinent pad has a pervious inner surface layer and impervious outer surface layer with both layers having edge portions connected together to form an envelope thereat. A high absorbent packet is contained within the formed envelope and overlies major areas of the impervious outer layer. A high loft porous webbed section is in initimate engagement with the high absorbent packet. The high absorbent packet has at least two juxtapositioned nonwoven webs of textile staple fibers with a layer of superabsorbent powder positioned between all of the adjacent webs. The edges of the webs are sealed together to prevent powder migration from the side. Each of the nonwoven webs of the high absorbent packet also includes a binder to impart sufficient strength to the nonwoven webs for facilitating handling and for allowing movement of the fiber under the expanding influence of the superabsorbent powder.

That which is claimed is: 
     
       1. An incontinent pad comprising a liquid impervious layer defining the outer surface of the pad, a nonwoven staple fiber face layer defining the inner surface of the pad, and wherein said liquid impervious layer and said textile staple fiber face layer each includes edge portions with the edge portions of both layers connected together to form an envelope thereat having a pervious inner surface and impervious outer surface, a high absorbent packet contained within said formed envelope and overlying major areas of the impervious outer layer, and a high loft porous webbed section substantially filling the envelope with one surface of the porous section being in intimate engagement with said high absorbent packet and the opposing surface of the face layer, said high absorbent packet comprising at least two juxtapositioned nonwoven webs of textile staple fibers, a layer of superabsorbent non-thermoplastic polymer powder positioned between all of said adjacent layers of said nonwoven webs of textile staple fibers and wherein the average size of the superabsorbent powder particles are between 40 and 150 microns in diameter, and said nonwoven webs have a weight of 1.0 to 3 ounces per square yard, and are formed of staple fibers having a length of between 0.5" to 3.0" and a denier of about 1 to 5 so as to provide a Frazier permeability test equipment value reading of less than 244 feet per minute air flow at a 0.5 inch water gauge pressure drop so as to prevent superabsorbent powder, particularly the smaller particle sizes, from migrating through the juxtapositioned nonwoven webs, said webs having edge portions sealed together to prevent escapement of the superabsorbent powder from within, and each of said nonwoven webs of textile staple fibers having binder means thereon to impart sufficient strength to the nonwoven web for facilitating the handling thereof. 
     
     
       2. The incontinent pad according to claim 1 wherein said binder means is a water soluble binder and is positioned on the innermost surfaces of said nonwoven webs for allowing movement of the fiber of said nonwoven webs under the expanding influence of the superabsorbent powder when the superabsorbent powder is wetted and inherently expanding so as to facilitate flow within the absorbent packet. 
     
     
       3. The incontinent pad according to claim 2 wherein said water soluble binder means is polyvinyl alcohol. 
     
     
       4. The incontinent pad according to claim 1 wherein said binder means is on the outer surfaces of said nonwoven webs, and said binder means being formed from fibrillated fibers and causing water received thereon to be spread over a wide area of the webs for thus obtaining contact with a wider area of said superabsorbent powder. 
     
     
       5. The incontinent pad according to claim 1 wherein said impervious outer surface is formed from a relatively thin plastic sheet material impervious to the passage of liquids and air therethrough. 
     
     
       6. The incontinent pad according to claim 1 wherein the superabsorbent powder between all of said adjacent layers of said nonwoven webs of textile staple fibers is in a discrete pattern motif. 
     
     
       7. The incontinent pad according to claim 1 wherein the high absorbent packet includes more than two nonwoven webs of textile staple fibers. 
     
     
       8. The incontinent pad according to claim 6 wherein the superabsorbent powder is positioned between all of said adjacent layers of the nonwoven webs of textile staple fibers in substantially uniform distribution. 
     
     
       9. The incontinent pad according to claim 6 wherein the superabsorbent powder is positioned between at least two adjacent layers of the nonwoven webs of textile staple fibers in a discrete pattern motif. 
     
     
       10. The incontinent pad according to claim 1 wherein said binder means on each nonwoven web of textile staple fiber is about 10% of the weight of the web. 
     
     
       11. The incontinent pad according to claim 1 wherein the weight of the superabsorbent powder applied between adjacent layers of said nonwoven webs of textile staple fibers is about 0.095 to 0.6 grams per square inch. 
     
     
       12. The incontinent pad according to claim 1 wherein the average size of the superabsorbent powder particles are about 90 microns. 
     
     
       13. The high absorbent packet according to claim 1 wherein said binder means is a water soluble binder and is positioned on the innermost surfaces of said nonwoven webs for allowing movement of the fiber of said nonwoven webs under the expanding influence of the superabsorbent powder when the superabsorbent powder is wetted and inherently expanding so as to facilitate flow within the absorbent packet. 
     
     
       14. The incontinent pad according to claim 1 wherein said binder means is on the outer surfaces of said nonwoven webs, and said binder means being formed from fibrillated fibers and causing water received thereon to be spread over a wide area of the webs for thus obtaining contact with a wider area of said superabsorbent powder. 
     
     
       15. An incontinent pad comprising a liquid impervious layer defining the outer surface of the pad, a nonwoven textile staple fiber face layer defining the inner surface of the pad, and wherein said liquid impervious layer and said textile staple fiber layer each includes edge portions with the edge portions of both layers connected together to form an envelope thereat having a pervious inner surface and impervious outer surface, a high absorbent packet contained within said formed envelope and overlying major areas of the impervious outer layer, and a high loft porous webbed section substantially filling the envelope with one surface of the porous section being in intimate engagement with said high absorbent packet and the opposing surface of the face layer, said high absorbent packet comprising at least two juxtapositioned nonwoven webs of textile staple fibers, a layer of superabsorbent non-thermoplastic polymer powder positioned between all of said adjacent layers of said nonwoven webs of textile staple fibers and wherein the average size of the superabsorbent powder particles are between 40 to 150 microns in diameter, and wherein said textile staple fibers forming said nonwoven webs have a staple length of between 0.5" to 0.3" a denier of about 1.5 and the weight of each nonwoven web of textile staple fibers is about 1.0 to 3 ounces per square yard so as to provide a Frazier permeability test equipment value reading of less than 244 feet per minute air flow at a 0.5 inch water gauge pressure drop so that the textile staple fibers forming the web prevent superabsorbent powder, particularly the smaller particle sizes, from migrating through the juxtapositioned webs, said webs having edge portions sealed together to prevent escapement of the superabsorbent powder from within, and each of said nonwoven webs of textile fibers having binder means thereon to impart sufficient strength to the 
     
     
       16. A high absorbent packet comprising at least two juxtapositioned nonwoven webs of textile staple fibers, a layer of superabsorbent non-thermoplastic polymer powder positioned between all of said adjacent layers of said nonwoven webs of textile staple fibers and wherein the average size of the superabsorbent powder particles are between 40 and 150 microns in diameter and said nonwoven webs have a weight of 1.0 to 3 ounces per square yard, and are formed of staple fibers having a length of between 0.5" to 3.0" and a denier of about 1 to 5 so as to provide a Frazier permeability test equipment value reading of less than 244 feet per minute air flow at 0.5 inch water gauge pressure drop so as to prevent superabsorbent powder, particularly the smaller particle sizes, from migrating through the smaller particle sizes, from migrating through the juxtapositioned nonwoven webs, said webs having edge portions sealed together to prevent escapement of the superabsorbent powder from within, and each of said nonwoven webs of textile staple fibers having binder means thereon to impart sufficient strength to the nonwoven web for facilitating the handling thereof. 
     
     
       17. The high absorbent packet according to claim 16 wherein the superabsorbent powder between all of said adjacent layers of said nonwoven webs of textile staple fibers is in a discrete pattern motif. 
     
     
       18. The high absorbent packet according to claim 16 wherein the packet includes more than two nonwoven webs of textile staple fibers. 
     
     
       19. The high absorbent packet according to claim 18 wherein the superabsorbent powder is positioned between all of said adjacent layers of the nonwoven webs of textile staple fibers in substantially uniform distribution. 
     
     
       20. The high absorbent packet according to claim 18 wherein the superabsorbent powder is positioned between at least two adjacent layers of the nonwoven webs of textile staple fibers in a discrete pattern motif. 
     
     
       21. The high absorbent packet according to claim 16 wherein said binder means on each nonwoven web of textile staple fibers is about 10% of the weight of a web. 
     
     
       22. The high absorbent packet according to claim 16 wherein the weight of the superabsorbent powder applied between the adjacent layers of said nonwoven webs of textile staple fibers is about 0.095 to 0.6 grams per square inch. 
     
     
       23. The high absorbent packet according to claim 16 wherein the average size of the superabsorbent powder particles is about 90 microns. 
     
     
       24. The high absorbent packet according to claim 16 wherein said superabsorbent powder is selected from the group consisting of polyacrylic acid and polyacrylic amid, a potassium based hydrolyzed starch, and sodium polyacrylate. 
     
     
       25. The high absorbent packet according to claim 17 wherein said water soluble binder means is polyvinyl alcohol.